Description

Daewoo D50S-2, D60S-2, D70S-2, D80S-2 2004 Service Manual – Factory OEM Documentation

You are holding a torque wrench on a Daewoo D50S-2, D60S-2, D70S-2, or D80S-2. The head bolts need 180 ft·lb on the first pass and a 90° turn on the second. Except the aftermarket PDF you pulled up says 175 ft·lb and a 60° turn. That’s a blown head gasket waiting to happen. I have seen it. That is why you need the Daewoo D50S-2, D60S-2, D70S-2, D80S-2 2004 Service Manual from a source that verifies every spec against the OEM print. This is not a reprint of some photocopied eBay special. This is the actual factory document used by dealers.

Engine Specifications and Performance Curves

Chapter 1 opens with engine specifications for the 5.8L DB58S diesel. You get bore, stroke, compression ratio, firing order, and injection timing. Then it gives you performance curves for three different transmission configurations: ECRFA (3-speed), ECRFB, and ECRFC (2-speed). Each curve shows horsepower and torque across the RPM range. If you are swapping engines or diagnosing a power loss, those curves let you compare your measured output against factory baseline. The curves are actual plots, not a table of numbers. That matters when you are trying to tell if a cylinder is down.

Torque Specs: Why You Need the Factory Numbers

The second page of the manual (page 2) is a dedicated torque specification sheet form SB2004E00. It covers every fastener on the engine: cylinder head bolts, main bearing caps, connecting rods, flywheel, and injection pump mounting. These numbers are what Daewoo released in December 1998 and remain unchanged for the 2004 model year. Do not trust a generic bolt chart. The cylinder head torque sequence is documented with the exact order and angle. Miss that and you are pulling the head again in 500 hours. Also check out the DAEWOO Service Manual Contents & Safety Guide for the full list of torque sheets across different Daewoo models.

Safety Regulations and General Repair Instructions

Section 1.4 covers five subsections: general notes, accident prevention, damage prevention, pollution prevention, and general repair instructions. The accident prevention part tells you never to work on a machine supported only by a jack. Use blocks or jack stands. It also says lower forks before service. These are not suggestions. I have seen a forklift drop because someone skipped that step. The manual also covers proper lifting procedures for heavy components. The 5.8L engine assembly weighs over 800 pounds. Read that section before you start.

TECHNICAL INFORMATION: Cylinder Block, Valves, and Fuel System

Chapter 2 goes deep. You get cylinder block type, piston and connecting rod specs, crankshaft dimensions, valve clearances, and lubrication system details. The fuel system section covers the injection pump, fuel filter, fuel requirements, and even a guide on how to select fuel oil by cetane number. Section 2.11 tells you how to check cylinder compression pressure and what the minimum values are. Section 2.15 has a full diagnosis and remedy table — common problems like hard starting, low power, and black smoke with the probable causes and fixes. If you are chasing a fuel delivery issue, this chapter saves you from replacing parts unnecessarily. For related models, see Daewoo Service Manual Contents SB4142E00 Nov 2004 which covers a different power train package.

Disassembly and Reassembly Procedures: 3.1 and 3.3

Section 3.1 details engine disassembly in six parts: major fixing nuts and bolts, main structure parts (two sections), rocker arm disassembly, cylinder head disassembly, and piston/connecting rod disassembly. Each step is illustrated with exploded views and identifies the tool needed. Section 3.3 covers reassembly in reverse order with torque values and sealant recommendations. The cylinder head tightening procedure is critical: you will find the final torque and angle in subsection 3.3.5. Do not guess. Page numbers are listed in the table of contents so you can flip right to the job you are doing. For larger Daewoo shop manuals, the Daewoo Musso Service Manual – Factory OEM Specs for 1465-Page Workbench is a different beast, but the quality of documentation is the same.

699 Pages of Factory Data

The manual is 699 pages. That includes the engine service manual, power train systems, vehicle systems, hydraulic and electric schematics, and operation/maintenance. You are getting the entire Service Manual Contents form SB4125E00 dated January 2004. The PDF is searchable — you can type “injection pump” and land on the exact page. No scrolling through 50 pages of fluff. The file name is DAEWOO_D50S-2-D60S-2-D70S-2-D80S-2_2004_Service_Manual_en-22009018725.pdf. That is the OEM file from the factory, not a third-party scan. For background on how diesel engines work, read the Internal Combustion Engine article on Wikipedia. For transmission fundamentals, see Manual Transmission — though these forklifts use a power shift transmission, the principles of gear reduction apply.

FAQ: Four Questions You Probably Have

Does this manual cover the D35S or D45S models?

No. This manual is specific to D50S-2, D60S-2, D70S-2, and D80S-2. The D35/40/45S-2 models are referenced in performance curves but the main procedures are for the larger chassis.

What torque values are listed? Are they imperial or metric?

Imperial. The torque specification sheet (SB2004E00) lists all values in foot-pounds. The manual was produced for the North American market.

Is this the complete factory manual or a condensed version?

Complete. 699 pages covering engine, power train, hydraulics, and electrics. The table of contents lists every form number and bookmark. Nothing is omitted.

Can I use this manual for a Daewoo forklift with a different engine, like the S4LE?

This manual covers only the DB58S 5.8L diesel. If your forklift has a different engine, you need the service manual for that specific engine model. The general information and safety sections may apply, but torque specs and disassembly will be wrong.

If you are working on a D50S-2, D60S-2, D70S-2, or D80S-2 from the 2004 model year, this is the manual you need. The OEM factory spec saves you from guesswork and rework. Access the Factory Manual from AutoRepairManuals and keep it on your tablet next to the lift.